Methods and systems for recovering phosphorus from wastewater including digestate recycle

ABSTRACT

Methods and systems for removal and recovery of phosphorus from wastewater and producing inorganic phosphorus complexes including digestate recycle.

CROSS REFERENCES TO RELATED APPLICATIONS

This application is a division of U.S. application Ser. No. 13/820,023,filed May 14, 2013, which is the national phase of InternationalApplication No. PCT/US2011/049784, filed Aug. 30, 2011, which claims thebenefit of U.S. Application No. 61/486,115, filed May 13, 2011, and U.S.Application No. 61/378,273, filed Aug. 30, 2010, each expresslyincorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

The presence of dissolved phosphate in industrial effluents andwastewater is a long-standing problem in the art. Phosphorus (referredto herein as “P”) is a non-renewable resource and an importantnon-substitutable macronutrient, existing in nature as phosphates invarious inorganic or organic forms, and ranging from the simple to thevery complex in terms of molecular structure. Because P is essential forall biological processes, there is concern that the current demand andexploitation (total annual production is about 20 million tons of P,derived from roughly 140 million tons of rock concentrates) of thisnon-renewable resource is not sustainable. Nearly all the P usedglobally is mined from a relatively small number ofcommercially-exploitable deposits, and it has been estimated that theglobal economic P reserves may last about 100 years at the current rateof extraction. Therefore, the world's P resources are finite and shouldbe used efficiently and in a sustainable way. Additionally, aside fromthe non-renewable resource aspect, there is need to improve Pmanagement, particularly from the environment protection perspectivebecause, for example, P-enrichment in receiving waters is associatedwith harmful algae blooms that affect the health and vitality ofwetlands and marine environments. Therefore, there is a pronounced needin the art to develop methods for increasing the life expectancy of theworld's limited P resources. There is a pronounced need in the art todevelop methods for recovery and recycling of P from industrialeffluents and wastewater.

Art-recognized P removal technologies applied to wastewater includechemical and biological processes. One chemical technology for P removaland recovery is crystallization of P in the form of struvite (magnesiumammonium phosphate hexahydrate or MgNH₄PO₄.6H₂O). Struvite iscrystalline and thus well suited for formation from effluent streams. Inaddition, as a granular product struvite is more compact than otherchemical precipitates, and it performs well as a slow-releasefertilizer. Struvite formation requires reaction between three solubleions in solution, Mg²⁺, NH₄ ⁺ and PO₄ ³⁻, to form precipitates with lowsolubility (struvite has a pK_(sp) of 12.6). Struvite precipitation iscontrolled by pH, supersaturation, and presence of impurities, such ascalcium. High pH (e.g., pH 8.5) and supersaturation of the three ionsare favorable to struvite formation.

As part of secondary sewage treatment, primary treated sewage is treatedwith air or oxygen. In the activated sludge process, microorganismsutilize oxygen to metabolize the incoming waste sewage thereby forming amixture of microorganisms and sewage (mixed liquor). This mixture isconducted to settling tanks for concentration to provide concentratedactivated sludge. A majority of the sludge is returned to the activatedsludge process and a separate portion of this sludge (waste activatedsludge) is removed from the activated sludge process and conducted to asludge handling system for further treatment and disposal.

In a typical wastewater treatment process, waste activated sludge isconducted to a first solids separation (centrifuge or other thickeningapparatus) for thickening, where the liquids are tapped off and returnedto the wastewater plant for treatment and the resultant thickened sludgeis conducted to an anaerobic digester with other sludge where it remainsfor a period of time before being conducted to a second solidsseparation (centrifuge or other dewatering apparatus) for dewatering.Struvite tends to form in the digester and other downstream equipmentbecause of the ammonia, magnesium and phosphorus present in the processstreams. This struvite is impractical to harvest and also has thedeleterious effect of being deposited on surfaces in the process systemcomponents.

Despite the advances in removing phosphorus from wastewater through theformation and recovery of struvite, a need exists for improved methodsand systems for wastewater treatment and struvite recovery thateliminate or significantly reduce nuisance struvite formation. Thepresent invention seeks to fulfill this need and provides furtherrelated advantages.

SUMMARY OF THE INVENTION

In one aspect, the invention provides methods for treating wastewaterand producing inorganic phosphorus.

In one embodiment, the invention provides a method for treatingwastewater and producing inorganic phosphorus, comprising:

(a) inducing a mixture of microorganisms containing phosphorus andmagnesium to release phosphorus and magnesium to provide a treatedmixture that includes phosphorus and magnesium;

(b) subjecting the treated mixture to solids separation to provide aphosphorus- and magnesium-reduced mixture and an ammonia-containing,phosphorus- and magnesium-rich liquid;

(c) conducting the ammonia-containing, phosphorus- and magnesium-richliquid to an inorganic phosphorus reactor to provide inorganicphosphorus;

(d) anaerobically treating the phosphorus- and magnesium-reduced mixtureto provide an ammonia-rich, phosphorus- and magnesium-reduced product;and

(e) conducting at least a portion of the ammonia-rich, phosphorus- andmagnesium-reduced product to the treated mixture prior to solidsseparation in step (b).

In one embodiment, the portion of the ammonia-rich, phosphorus- andmagnesium-reduced product that is conducted to the treated mixture priorto solids separation in step (b) is an ammonia-rich, phosphorus- andmagnesium-reduced liquid produced by solids separation of theammonia-rich, phosphorus- and magnesium-reduced product. In oneembodiment of this method, the method further comprises conducting atleast a portion of the ammonia-rich, phosphorus- and magnesium-reducedliquid to a second inorganic phosphorus reactor to provide inorganicphosphorus.

In one embodiment, the portion of the ammonia-rich, phosphorus- andmagnesium-reduced product that is conducted to the treated mixture priorto solids separation in step (b) is drawn directly from theammonia-rich, phosphorus- and magnesium-reduced mixture conducted fromthe digester. In one embodiment of this method, the method furthercomprises conducting at least a portion of the ammonia-rich, phosphorus-and magnesium-reduced product to solids separation to provide anammonia-rich, phosphorus- and magnesium-reduced liquid; and optionallyconducting the ammonia-rich, phosphorus- and magnesium-reduced liquid toa second inorganic phosphorus reactor to provide inorganic phosphorus.

In another embodiment, the invention provides a method for treatingwastewater and producing inorganic phosphorus, comprising:

(a) inducing a mixture of microorganisms containing phosphorus andmagnesium to release phosphorus and magnesium to provide a treatedmixture that includes phosphorus and magnesium;

(b) subjecting the treated mixture to solids separation to provide aphosphorus- and magnesium-reduced mixture and an ammonia-containing,phosphorus- and magnesium-rich liquid;

(c) conducting the ammonia-containing, phosphorus- and magnesium-richliquid to an inorganic phosphorus reactor to provide inorganicphosphorus;

(d) anaerobically treating the phosphorus- and magnesium-reduced mixtureto provide an ammonia-rich, phosphorus- and magnesium-reduced mixture;and

(e) separating the ammonia-rich, phosphorus- and magnesium-reducedmixture to provide biosolids and an ammonia-rich, phosphorus- andmagnesium-reduced liquid; and

(f) conducting the ammonia-rich, phosphorus- and magnesium-reducedliquid to the treated mixture prior to solids separation in step (b).

In one embodiment, the method further comprises adjusting the pH of thecontents of the inorganic phosphorus reactor. In one embodiment, themethod further comprises adding magnesium to the contents of theinorganic phosphorus reactor. In one embodiment, the method furthercomprises conducting liquid from the inorganic phosphorus reactor to theprocess headworks.

In another embodiment, the invention provides a method for treatingwastewater and producing inorganic phosphorus, comprising:

(a) inducing a mixture of microorganisms containing phosphorus andmagnesium to release phosphorus and magnesium to provide a treatedmixture that includes phosphorus and magnesium;

(b) subjecting the treated mixture to solids separation to provide aphosphorus- and magnesium-reduced mixture and an ammonia-containing,phosphorus- and magnesium-rich liquid;

(c) conducting the ammonia-containing, phosphorus- and magnesium-richliquid to an inorganic phosphorus reactor to provide inorganicphosphorus;

(d) anaerobically treating the phosphorus- and magnesium-reduced mixtureto provide an ammonia-rich, phosphorus- and magnesium-reduced mixture;

(e) separating the ammonia-rich, phosphorus- and magnesium-reducedmixture to provide biosolids and an ammonia-rich, phosphorus- andmagnesium-reduced liquid;

(f) conducting at least a first portion the ammonia-rich, phosphorus-and magnesium-reduced liquid to the treated mixture prior to solidsseparation in step (b); and

(g) optionally conducting at least a second portion of the ammonia-rich,phosphorus- and magnesium-reduced liquid to a second inorganicphosphorus reactor to provide inorganic phosphorus.

In certain embodiments, the method further comprises adjusting the pH ofthe contents of one or both of the inorganic phosphorus reactors. Incertain embodiments, the method further comprises adding magnesium tothe contents of one or both of the inorganic phosphorus reactors. Incertain embodiments, the method further comprises conducting liquid fromone or both of the inorganic phosphorus reactors to the processheadworks.

In a further embodiment, the invention provides a method for treatingwastewater and producing inorganic phosphorus, comprising:

(a) inducing a mixture of microorganisms containing phosphorus andmagnesium to release phosphorus and magnesium to provide a treatedmixture that includes phosphorus and magnesium;

(b) subjecting the treated mixture to solids separation to provide aphosphorus- and magnesium-reduced mixture and an ammonia-containing,phosphorus- and magnesium-rich liquid;

(c) conducting the ammonia-containing, phosphorus- and magnesium-richliquid to a first inorganic phosphorus reactor to provide inorganicphosphorus;

(d) anaerobically treating the phosphorus- and magnesium-reduced mixtureto provide an ammonia-rich, phosphorus- and magnesium-reduced mixture;

(e) conducting at least a first portion of the ammonia-rich, phosphorus-and magnesium-reduced mixture to the treated mixture prior to solidsseparation in step (b);

(f) separating at least a second portion of the ammonia-rich,phosphorus- and magnesium-reduced mixture to provide biosolids and anammonia-rich, phosphorus- and magnesium-reduced liquid; and

(g) optionally conducting the ammonia-rich, phosphorus- andmagnesium-reduced liquid to a second inorganic phosphorus reactor toprovide inorganic phosphorus.

In certain embodiments, the method further comprises adjusting the pH ofthe contents of one or both of the inorganic phosphorus reactors. Incertain embodiments, the method further comprises adding magnesium tothe contents of one or both of the inorganic phosphorus reactors. Incertain embodiments, the method further comprises conducting liquid fromone or both of the inorganic phosphorus reactors to the processheadworks.

In another aspect, the invention provides systems for treatingwastewater and producing inorganic phosphorus.

In one embodiment, the invention provides a system for treatingwastewater and producing inorganic phosphorus, comprising:

(a) a first conduit for introducing a material into a first solidsseparator;

(b) a first solids separator for separating the material into a firstliquid and a first mixture;

(c) an inorganic phosphorus reactor for making inorganic phosphorus;

(d) a second conduit intermediate the first solids separator and theinorganic phosphorus reactor for conducting the first liquid from thefirst solids separator to the inorganic phosphorus reactor;

(e) a digester for anaerobically treating the first mixture to provide asecond mixture;

(f) a third conduit intermediate the first solids separator and thedigester for conducting the first mixture from the first solidsseparator to the digester;

(g) a second solids separator for separating the second mixture into asecond liquid and biosolids;

(h) a fourth conduit intermediate the digester and the second solidsseparator for conducting the second mixture from the digester to thesecond solids separator; and

(i) a fifth conduit intermediate the second solids separator and thefirst conduit for conducting the second liquid to the first conduit tocombine the second liquid with the material.

In another embodiment, the invention provides a system for treatingwastewater and producing inorganic phosphorus, comprising:

(a) a first conduit for introducing a material into a first solidsseparator;

(b) a first solids separator for separating the material into a firstliquid and a first mixture;

(c) a first inorganic phosphorus reactor for making inorganicphosphorus;

(d) a second conduit intermediate the first solids separator and thefirst inorganic phosphorus reactor for conducting the first liquid fromthe first solids separator to the first inorganic phosphorus reactor;

(e) a digester for anaerobically treating the first mixture to provide asecond mixture;

(f) a third conduit intermediate the first solids separator and thedigester for conducting the first mixture from the first solidsseparator to the digester;

(g) a second solids separator for separating the second mixture into asecond liquid and biosolids;

(h) a fourth conduit intermediate the digester and the second solidsseparator for conducting the second mixture from the digester to thesecond solids separator;

(i) a second inorganic phosphorus reactor for making inorganicphosphorus;

(j) a fifth conduit intermediate the second solids separator and thefirst conduit for conducting a first portion of the second liquid fromthe second solids separator to the first conduit to combine the secondliquid with the material; and (k) a sixth conduit intermediate thesecond solids separator and the second inorganic phosphorus reactor forconducting a second portion of the second liquid to the second inorganicphosphorus reactor.

In a further embodiment, the invention provides a system for treatingwastewater and producing inorganic phosphorus, comprising:

(a) a first conduit for introducing a material into a first solidsseparator;

(b) a first solids separator for separating the material into a firstliquid and a first mixture;

(c) a first inorganic phosphorus reactor for making inorganicphosphorus;

(d) a second conduit intermediate the first solids separator and thefirst inorganic phosphorus reactor for conducting the first liquid fromthe first solids separator to the first inorganic phosphorus reactor;

(e) a digester for anaerobically treating the first mixture to provide asecond mixture;

(f) a third conduit intermediate the first solids separator and thedigester for conducting the first mixture from the first solidsseparator to the digester;

(g) a fourth conduit intermediate the digester and the first conduit forconducting a first portion of the second mixture from the digester tothe first conduit to combine the second mixture with the material;

(h) a second solids separator for separating a second portion of thesecond mixture into a second liquid and biosolids;

(i) a fifth conduit intermediate the digester and the second solidsseparator for conducting the second portion of the second mixture fromthe digester to the second solids separator;

(j) a second inorganic phosphorus reactor for making inorganicphosphorus; and

(k) a sixth conduit intermediate the second solids separator and thesecond inorganic phosphorus reactor for conducting the second liquid tothe second inorganic reactor.

DESCRIPTION OF THE DRAWINGS

The foregoing aspects and many of the attendant advantages of thisinvention will become more readily appreciated as the same become betterunderstood by reference to the following detailed description, whentaken in conjunction with the accompanying drawings.

FIG. 1 is a schematic illustration of a representative method of theinvention for treating wastewater and producing inorganic phosphorus.

FIG. 2 is a schematic illustration of a representative method of theinvention for treating wastewater and producing inorganic phosphorus.

FIG. 3 is a schematic illustration of a representative method of theinvention for treating wastewater and producing inorganic phosphorus.

FIG. 4 is a schematic illustration of a representative system of theinvention for treating wastewater and producing inorganic phosphorus.

FIG. 5 is a schematic illustration of a representative system of theinvention for treating wastewater and producing inorganic phosphorus.

FIG. 6 is a schematic illustration of a representative system of theinvention for treating wastewater and producing inorganic phosphorus.

DETAILED DESCRIPTION OF THE INVENTION

The invention provides methods and systems for removing and recoveringof phosphorus from wastewater through the formation of inorganicphosphorus (e.g., struvite). The methods and systems advantageouslyremove phosphorus from wastewater treatment streams and provideinorganic phosphorus as a valuable byproduct.

In typical a wastewater treatment process, phosphorus removal fromwastewater is ultimately accomplished by the generation ofphosphorus-containing biosolids that are removed from the system. In thetypical process, microorganisms are induced to grow, thereby taking upphosphorus into their cell mass. These microorganisms are then separatedfrom the wastewater in the form of waste activated sludge (“WAS”),thereby removing the phosphorus from the wastewater. To reduce thevolume of the sludge, it is anaerobically digested, which,unfortunately, releases some of the phosphorus from the cells. Thus,when the digestate is then subjected to solids separation to extract thephosphorus-containing biosolids, the liquid exiting the solidsseparation also contains some amount of phosphorus, which must berecycled to the headworks. Disadvantages of this typical process includean increased demand on the biological phosphorus release step (due tothe recycled phosphorus) and the formation of phosphorus-containingbiosolids, which must be disposed of in an acceptable manner thatdepends on the biosolids' phosphorus content.

The present invention provides an alternative to conventional wastewatertreatment processes and advantageously provides for efficient andeffective phosphorus removal from wastewater. The invention provides forthe formation of an inorganic phosphorus product (i.e., struvite) fromwastewater process streams thereby efficiently and effectively removingphosphorus from the process streams. Removal of phosphorus from theprocess streams by the methods and systems of the invention reduces theamount of phosphorus recycled to the process headworks. This in turndecreases the phosphorus load on the biological phosphorus release step.Furthermore, phosphorus removal from the process streams by the methodsand systems of the invention also reduces the amount of phosphorus inthe bio solids. A third benefit associated with the methods and systemsof the invention is that through phosphorus removal, the formation ofnuisance struvite, struvite that is impractical to harvest and that hasa deleterious effect once deposited on process system componentsurfaces, is substantially minimized. Because of the significance andbenefits of phosphorus removal, the methods and systems of the inventionoffer an advantageous alternative to conventional wastewater treatmentprocesses.

The present invention also specifically addresses the problems ofnuisance struvite formation and external alkalinity demand associatedwith conventional wastewater treatment processes.

In a typical wastewater treatment process, waste activated sludge isconducted to a solids separation for thickening, where the liquids aretapped off and returned to the wastewater plant for treatment and theresultant thickened sludge is conducted to an anaerobic digester withother sludge where it remains for a period of time before beingconducted to a second solids separation. Struvite tends to form in thedigester and other downstream equipment because of the presence ofammonia, magnesium, and phosphorus under pH conditions effective for itsformation.

In the methods and systems of the invention, the alkalinity of theprocess stream entering the first solids separation step, andconsequently the digester, is increased by recycling at least a portionof the alkaline product produced by the digester to the first solidsseparator. The increase in alkalinity is effective to resist pHdepression in the digester, maintaining pH conditions required foreffective digestion, and prevents the digestion from “souring out.”

In the practice of the present invention, at least a portion of thealkaline ammonia-rich, phosphorus- and magnesium-reduced productproduced from anaerobic digestion is conducted to and combined with thephosphorus- and magnesium-containing treated mixture produced frommicroorganism phosphorus release prior to the first solids separation.As noted above, the introduction of this alkaline material to thetreated mixture significantly reduces the alkaline demand (i.e.,satisfies or reduces the need of adding an alkaline material, such asmagnesium hydroxide, to the digester or to its inflow) prior to thefirst solids separation and eliminates or significantly reduces nuisancestruvite formation in downstream processing due to the reduction inmagnesium input.

In one embodiment, the invention provides a method for treatingwastewater and producing inorganic phosphorus, comprising:

(a) inducing a mixture of microorganisms containing phosphorus andmagnesium to release phosphorus and magnesium to provide a treatedmixture that includes phosphorus and magnesium;

(b) subjecting the treated mixture to solids separation to provide aphosphorus- and magnesium-reduced mixture and an ammonia-containing,phosphorus- and magnesium-rich liquid;

(c) conducting the ammonia-containing, phosphorus- and magnesium-richliquid to an inorganic phosphorus reactor to provide inorganicphosphorus;

(d) anaerobically treating the phosphorus- and magnesium-reduced mixtureto provide an ammonia-rich, phosphorus- and magnesium-reduced product;and

(e) conducting at least a portion of the ammonia-rich, phosphorus- andmagnesium-reduced product to the treated mixture prior to solidsseparation in step (b).

In one embodiment, the portion of the ammonia-rich, phosphorus- andmagnesium-reduced product that is conducted to the treated mixture priorto solids separation in step (b) is an ammonia-rich, phosphorus- andmagnesium-reduced liquid produced by solids separation of theammonia-rich, phosphorus- and magnesium-reduced product. In oneembodiment of this method, the method further comprises conducting atleast a portion of the ammonia-rich, phosphorus- and magnesium-reducedliquid to a second inorganic phosphorus reactor to provide inorganicphosphorus.

In one embodiment, the portion of the ammonia-rich, phosphorus- andmagnesium-reduced product that is conducted to the treated mixture priorto solids separation in step (b) is drawn directly from theammonia-rich, phosphorus- and magnesium-reduced mixture conducted fromthe digester. In one embodiment of this method, the method furthercomprises conducting at least a portion of the ammonia-rich, phosphorus-and magnesium-reduced product to solids separation to provide anammonia-rich, phosphorus- and magnesium-reduced liquid; and optionallyconducting the ammonia-rich, phosphorus- and magnesium-reduced liquid toa second inorganic phosphorus reactor to provide inorganic phosphorus.

Schematic illustrations of representative methods of the invention fortreating wastewater and producing inorganic phosphorus are shown inFIGS. 1-3. Schematic illustrations of representative systems of theinvention for treating wastewater and producing inorganic phosphorus areshown in FIGS. 4-6.

Referring to FIG. 1, a mixture of microorganisms containing phosphorusand magnesium are induced to release phosphorus and magnesium intoliquid to provide a treated mixture that includes phosphorus andmagnesium (waste-activated sludge, WAS). The treated mixture is combinedwith the ammonia-rich, phosphorus- and magnesium-reduced liquid that isseparated from the product of anaerobic digestion described below, andthe combination subjected to solids separation (SS1) to provide aphosphorus- and magnesium-reduced mixture and an ammonia-containing,phosphorus- and magnesium-rich liquid.

The phosphorus- and magnesium-reduced mixture (S+L) is subjected toanaerobic digestion, where ammonia is released, to provide anammonia-rich, phosphorus- and magnesium-reduced mixture containingsuspended solids in liquid (S+L). At this point substantially nocombination of phosphorus and magnesium occurs because of the relativelylow concentration of each and because the pH is low.

Ammonia-rich, phosphorus- and magnesium-reduced liquid (L) and biosolids(S) are separated from the ammonia-rich, phosphorus- andmagnesium-reduced mixture by solids separation (SS2). Solids separationcan be achieved by a variety of conventional means including gravitybelts, filters, and centrifuges. The biosolids are removed from thesystem.

As noted above, the ammonia-rich, phosphorus- and magnesium-reducedliquid is combined with the treated mixture and subjected to solidseparations (SS1) to provide an ammonia-containing, phosphorus- andmagnesium-rich liquid (L) that is conducted to the inorganic phosphorusreactor (SR) where inorganic phosphorus is formed. There, magnesium isoptionally added, if necessary, and pH is optionally adjusted (e.g.,addition of sodium hydroxide or other suitable pH booster), ifnecessary, to provide inorganic phosphorus. The inorganic phosphorus(e.g., struvite) is collected from the reactor and liquid from thereactor is optionally conducted to the process headworks. The solidsseparated from the ammonia-containing, phosphorus- and magnesium-richliquid are conducted to the digester.

Thus, in one embodiment, the method includes the following steps:

(a) inducing a mixture of microorganisms containing phosphorus andmagnesium to release phosphorus and magnesium to provide a treatedmixture that includes phosphorus and magnesium;

(b) subjecting the treated mixture to solids separation to provide aphosphorus- and magnesium-reduced mixture and an ammonia-containing,phosphorus- and magnesium-rich liquid;

(c) conducting the ammonia-containing, phosphorus- and magnesium-richliquid to an inorganic phosphorus reactor to provide inorganicphosphorus;

(d) anaerobically treating the phosphorus- and magnesium-reduced mixtureto provide an ammonia-rich, phosphorus- and magnesium-reduced mixture;and

(e) separating the ammonia-rich, phosphorus- and magnesium-reducedmixture to provide biosolids and an ammonia-rich, phosphorus- andmagnesium-reduced liquid; and

(f) conducting the ammonia-rich, phosphorus- and magnesium-reducedliquid to the treated mixture prior to solids separation in step (b).

In one embodiment, the method further comprises adjusting the pH of thecontents of the inorganic phosphorus reactor. In one embodiment, themethod further comprises adding magnesium to the contents of theinorganic phosphorus reactor. In one embodiment, the method furthercomprises conducting liquid from the inorganic phosphorus reactor to theprocess headworks.

A second embodiment of the invention is illustrated schematically inFIG. 2. Referring to FIG. 2, a mixture of microorganisms containingphosphorus and magnesium are induced to release phosphorus and magnesiuminto liquid to provide a treated mixture that includes phosphorus andmagnesium (waste-activated sludge, WAS). The treated mixture is combinedwith a portion of the ammonia-rich, phosphorus- and magnesium-reducedliquid that is separated from the product of anaerobic digestiondescribed below, and the combination subjected to solids separation(SS1) to provide a phosphorus- and magnesium-reduced mixture and anammonia-containing, phosphorus- and magnesium-rich liquid.

The phosphorus- and magnesium-reduced mixture is subjected to anaerobicdigestion, where ammonia is released, to provide an ammonia-rich,phosphorus- and magnesium-reduced mixture containing suspended solids inliquid (S+L). At this point substantially no combination of phosphorusand magnesium occurs because of the relatively low concentration of eachand because the pH is low.

Ammonia-rich, phosphorus- and magnesium-reduced liquid (L) is separatedfrom the ammonia-rich, phosphorus- and magnesium-reduced mixture bysolids separation (SS2) to provide biosolids (S). Solids separation canbe achieved by a variety of conventional means including gravity belts,filters, and centrifuges. The biosolids are removed from the system.

In this embodiment, it is appreciated that the amount of ammonianecessary for inorganic phosphorus formation in the inorganic phosphorusreactor (SR1) may be less than the amount of ammonia present in theammonia-rich, phosphorus- and magnesium-reduced liquid produced from thesecond solids separator (SS2). Accordingly, in this embodiment, only aportion of the ammonia-rich, phosphorus- and magnesium-reduced liquidproduced from the second solids separator (SS2) is conducted to thetreated mixture prior to solids separation (SS1). The remainder of thestream can be conducted from the system, further treated by, forexample, being conducted to a second inorganic phosphorus reactor (SR2),or conducted to the system headworks. Magnesium is optionally added, ifnecessary, and pH is optionally adjusted (e.g., addition of sodiumhydroxide or other suitable pH booster), if necessary, to provideinorganic phosphorus.

As noted above, a portion of the ammonia-rich, phosphorus- andmagnesium-reduced liquid from the second solids separator (SS2) and thetreated mixture from step (a) are subjected to solid separations (SS1)to provide an ammonia-containing, phosphorus- and magnesium-rich liquid(L) that is conducted to the inorganic phosphorus reactor (SR1) whereinorganic phosphorus is formed. There, magnesium is optionally added, ifnecessary, and pH is optionally adjusted (e.g., addition of sodiumhydroxide or other suitable pH booster), if necessary, to provideinorganic phosphorus. The inorganic phosphorus (e.g., struvite) iscollected from the reactor and liquid from the reactor is optionallyconducted to the process headworks. The solids separated from theammonia-containing, phosphorus- and magnesium-rich liquid are conductedto the digester.

Thus, in one embodiment, the method includes the following steps:

(a) inducing a mixture of microorganisms containing phosphorus andmagnesium to release phosphorus and magnesium to provide a treatedmixture that includes phosphorus and magnesium;

(b) subjecting the treated mixture to solids separation to provide aphosphorus- and magnesium-reduced mixture and an ammonia-containing,phosphorus- and magnesium-rich liquid;

(c) conducting the ammonia-containing, phosphorus- and magnesium-richliquid to an inorganic phosphorus reactor to provide inorganicphosphorus; (d) anaerobically treating the phosphorus- andmagnesium-reduced mixture to provide an ammonia-rich, phosphorus- andmagnesium-reduced mixture;

(e) separating the ammonia-rich, phosphorus- and magnesium-reducedmixture to provide biosolids and an ammonia-rich, phosphorus- andmagnesium-reduced liquid;

(f) conducting at least a first portion the ammonia-rich, phosphorus-and magnesium-reduced liquid to the treated mixture prior to solidsseparation in step (b); and

(g) optionally conducting at least a second portion of the ammonia-rich,phosphorus- and magnesium-reduced liquid to a second inorganicphosphorus reactor to provide inorganic phosphorus.

In certain embodiments, the method further comprises adjusting the pH ofthe contents of one or both of the inorganic phosphorus reactors. Incertain embodiments, the method further comprises adding magnesium tothe contents of one or both of the inorganic phosphorus reactors. Incertain embodiments, the method further comprises conducting liquid fromone or both of the inorganic phosphorus reactors to the processheadworks.

A third embodiment of the invention is illustrated schematically in FIG.3. Referring to FIG. 3, a mixture of microorganisms containingphosphorus and magnesium are induced to release phosphorus and magnesiuminto liquid to provide a treated mixture that includes phosphorus andmagnesium (waste-activated sludge, WAS). The treated mixture and aportion of the ammonia-rich, phosphorus- and magnesium-reduced mixture,which is the product of anaerobic digestion described below, issubjected to solids separation (SS1) to provide a phosphorus- andmagnesium-reduced mixture and an ammonia-containing, phosphorus- andmagnesium-rich liquid.

In this embodiment, it is appreciated that the amount of ammonianecessary for inorganic phosphorus formation in the inorganic phosphorusreactor (SR1) may be less than the amount of ammonia present in theammonia-rich, phosphorus- and magnesium-reduced mixture produced fromthe digester. Accordingly, in this embodiment, a portion of theammonia-rich, phosphorus- and magnesium-reduced mixture produced fromthe digester and the treated mixture are subjected to solids separation(SS1). The remainder of the ammonia-rich, phosphorus- andmagnesium-reduced mixture may be subject to solids separation (SS2) toprovide an ammonia-rich, phosphorus- and magnesium-reduced liquid (L)and biosolids (S). Solids separation can be achieved by a variety ofconventional means including gravity belts, filters, and centrifuges.The biosolids are removed from the system.

The ammonia-rich, phosphorus- and magnesium-reduced liquid can beconducted from the system, further treated by, for example, beingconducted to a second inorganic phosphorus reactor (SR2), or conductedto the system headworks. Magnesium is optionally added, if necessary,and pH is optionally adjusted (e.g., addition of sodium hydroxide orother suitable pH booster), if necessary, to provide inorganicphosphorus in the second inorganic phosphorus reactor.

As noted above, a portion of the ammonia-rich, phosphorus- andmagnesium-reduced mixture from the digester and the treated mixture fromstep (a) are subjected to solid separations (SS1) to provide anammonia-containing, phosphorus- and magnesium-rich liquid (L) that isconducted to the inorganic phosphorus reactor (SR1) where inorganicphosphorus is formed. There, magnesium is optionally added, ifnecessary, and pH is optionally adjusted (e.g., addition of sodiumhydroxide or other suitable pH booster), if necessary, to provideinorganic phosphorus. The inorganic phosphorus (e.g., struvite) iscollected from the reactor and liquid from the reactor is optionallyconducted to the process headworks. The solids separated from theammonia-containing, phosphorus- and magnesium-rich liquid are conductedto the digester.

Thus, in one embodiment, the method includes the following steps:

(a) inducing a mixture of microorganisms containing phosphorus andmagnesium to release phosphorus and magnesium to provide a treatedmixture that includes phosphorus and magnesium;

(b) subjecting the treated mixture to solids separation to provide aphosphorus- and magnesium-reduced mixture and an ammonia-containing,phosphorus- and magnesium-rich liquid;

(c) conducting the ammonia-containing, phosphorus- and magnesium-richliquid to a first inorganic phosphorus reactor to provide inorganicphosphorus;

(d) anaerobically treating the phosphorus- and magnesium-reduced mixtureto provide an ammonia-rich, phosphorus- and magnesium-reduced mixture;

(e) conducting at least a first portion of the ammonia-rich, phosphorus-and magnesium-reduced mixture to the treated mixture prior to solidsseparation in step (b);

(f) separating at least a second portion of the ammonia-rich,phosphorus- and magnesium-reduced mixture to provide biosolids and anammonia-rich, phosphorus- and magnesium-reduced liquid; and

(g) optionally conducting the ammonia-rich, phosphorus- andmagnesium-reduced liquid to a second inorganic phosphorus reactor toprovide inorganic phosphorus.

In certain embodiments, the method further comprises adjusting the pH ofthe contents of one or both of the inorganic phosphorus reactors. Incertain embodiments, the method further comprises adding magnesium tothe contents of one or both of the inorganic phosphorus reactors. Incertain embodiments, the method further comprises conducting liquid fromone or both of the inorganic phosphorus reactors to the processheadworks.

In another aspect, the invention provides systems for treatingwastewater and producing inorganic phosphorus are provided. The systemsare effective in carrying out the methods of the invention. In thesystems, the highly alkaline ammonia-rich, phosphorus- and magnesiumreduced product produced from anaerobic digestion is conducted to andcombined with the phosphorus- and magnesium-containing treated mixtureproduced from microorganism phosphorus release prior to the first solidsseparation. As noted above, the introduction of this alkaline materialto the treated mixture satisfies or significantly reduces the alkalinedemand prior to the first solids separation and eliminates orsignificantly reduces nuisance struvite formation in downstreamprocessing.

A representative system of the invention is illustrated schematically inFIG. 4. Referring to FIG. 4, system 400 comprises:

(a) a first conduit 410 for introducing a material into a first solidsseparator 110;

(b) a first solids separator 110 for separating the material into afirst liquid and a first mixture;

(c) an inorganic phosphorus reactor 120 for making inorganic phosphorus;

(d) a second conduit 420 intermediate the first solids separator 110 andthe inorganic phosphorus reactor 120 for conducting the first liquidfrom the first solids separator to the inorganic phosphorus reactor;

(e) a digester 130 for anaerobically treating the first mixture toprovide a second mixture;

(f) a third conduit 430 intermediate the first solids separator 110 andthe digester 130 for conducting the first mixture from the first solidsseparator to the digester;

(g) a second solids separator 140 for separating the second mixture intoa second liquid and biosolids;

(h) a fourth conduit 440 intermediate the digester 130 and the secondsolids separator 140 for conducting the second mixture from the digesterto the second solids separator; and

(i) a fifth conduit 450 intermediate the second solids separator 140 andthe first conduit 410 for conducting the second liquid to the firstconduit to combine the second liquid with the material.

Second solids separator 140 further includes conduit 450 for conductingbiosolids from the system.

Inorganic phosphorus reactor 120 further includes conduit 470 fordirecting inorganic phosphorus reactor liquid output from the reactor.

A second representative system of the invention is illustratedschematically in FIG. 5. Referring to FIG. 5, system 500 comprises:

(a) a first conduit 510 for introducing a material into a first solidsseparator 110;

(b) a first solids separator 110 for separating the material into afirst liquid and a first mixture;

(c) a first inorganic phosphorus reactor 120 for making inorganicphosphorus;

(d) a second conduit 520 intermediate the first solids separator 110 andthe first inorganic phosphorus reactor 120 for conducting the firstliquid from the first solids separator to the first inorganic phosphorusreactor;

(e) a digester 130 for anaerobically treating the first mixture toprovide a second mixture;

(f) a third conduit 530 intermediate the first solids separator 110 andthe digester 130 for conducting the first mixture from the first solidsseparator to the digester;

(g) a second solids separator 140 for separating the second mixture intoa second liquid and biosolids;

(h) a fourth conduit 540 intermediate the digester 130 and the secondsolids separator 140 for conducting the second mixture from the digesterto the second solids separator;

(i) a second inorganic phosphorus reactor 150 for making inorganicphosphorus;

(j) a fifth conduit 550 intermediate the second solids separator 140 andthe first conduit 510 for conducting a first portion of the secondliquid from the second solids separator to the first conduit to combinethe second liquid with the material; and

(k) a sixth conduit 560 intermediate the second solids separator 140 andthe second inorganic phosphorus reactor 150 for conducting a secondportion of the second liquid to the second inorganic phosphorus reactor.

Second solids separator 140 further includes conduit 570 for conductingbiosolids from the system.

Inorganic phosphorus reactors 120 and 150 further include conduits 590and 580, respectively, for directing inorganic phosphorus reactor liquidoutput from the reactor.

A third representative system of the invention is illustratedschematically in FIG. 6. Referring to FIG. 6, system 600 comprises:

(a) a first conduit 610 for introducing a material into a first solidsseparator 110;

(b) a first solids separator 110 for separating the material into afirst liquid and a first mixture;

(c) a first inorganic phosphorus reactor 120 for making inorganicphosphorus;

(d) a second conduit 620 intermediate the first solids separator 110 andthe first inorganic phosphorus reactor 120 for conducting the firstliquid from the first solids separator to the first inorganic phosphorusreactor;

(e) a digester 130 for anaerobically treating the first mixture toprovide a second mixture;

(f) a third conduit 630 intermediate the first solids separator 110 andthe digester 130 for conducting the first mixture from the first solidsseparator to the digester;

(g) a fourth conduit 640 intermediate the digester 130 and the firstconduit 610 for conducting a first portion of the second mixture fromthe digester to the first conduit to combine the second mixture with thematerial;

(h) a second solids separator 140 for separating a second portion of thesecond mixture into a second liquid and biosolids;

(i) a fifth conduit 650 intermediate the digester 130 and the secondsolids separator 140 for conducting the second portion of the secondmixture from the digester to the second solids separator;

(j) a second inorganic phosphorus reactor 150 for making inorganicphosphorus; and

(k) a sixth conduit 660 intermediate the second solids separator 140 andthe second inorganic phosphorus reactor 150 for conducting the secondliquid to the second inorganic reactor.

Second solids separator 140 further includes conduit 670 for conductingbiosolids from the system.

Inorganic phosphorus reactors 120 and 150 further include conduits 690and 680, respectively, for directing inorganic phosphorus reactor liquidoutput from the reactor.

In the systems described herein, it will be appreciated that the inletends of conduits can connect either to a source conduit or to the systemcomponent (e.g., digester) from which the source conduit is flowing, andthat the outlet ends of conduits can connect either to a destinationconduit or to the system into which the destination conduit flows. Asdescribed herein, when one configuration is stated (e.g., a conduitconnecting on its inlet end to a source conduit) it is also intendedthat it include the other (that same conduit connecting on its inlet endto the equipment from which the specified source conduit is flowing).

In the methods and systems of the invention, ammonia is combined withphosphorus and magnesium to produce inorganic phosphorus (e.g.,struvite). It will be appreciated that the nature of the ammonia willdepend on the pH of the environment of the process streams in which theammonia is present. For example, at lower pH, ammonia will be in theform of ammonium (NH₄ ⁺) and can be associated with counterions (e.g.,sulfate, SO₄ ²).

While the preferred embodiment of the invention has been illustrated anddescribed, it will be appreciated that various changes can be madetherein without departing from the spirit and scope of the invention.

1. A system for producing inorganic phosphorus from wastewater,comprising: (a) a first conduit for introducing a material into a firstsolids separator; (b) a first solids separator for separating thematerial into a first liquid and a first mixture; (c) an inorganicphosphorus reactor for making inorganic phosphorus; (d) a second conduitintermediate the first solids separator and the inorganic phosphorusreactor for conducting the first liquid from the first solids separatorto the inorganic phosphorus reactor; (e) a digester for anaerobicallytreating the first mixture to provide a second mixture; (f) a thirdconduit intermediate the first solids separator and the digester forconducting the first mixture from the first solids separator to thedigester; (g) a second solids separator for separating the secondmixture into a second liquid and biosolids; (h) a fourth conduitintermediate the digester and the second solids separator for conductingthe second mixture from the digester to the second solids separator; and(i) a fifth conduit intermediate the second solids separator and thefirst conduit for conducting the second liquid to the first conduit tocombine the second liquid with the material.
 2. The system of claim 1,wherein the material is waste-activated sludge.
 3. The system of claim1, wherein the inorganic phosphorus is a magnesium ammonium phosphatehexahydrate.
 4. A system for producing inorganic phosphorus fromwastewater, comprising: (a) a first conduit for introducing a materialinto a first solids separator; (b) a first solids separator forseparating the material into a first liquid and a first mixture; (c) afirst inorganic phosphorus reactor for making inorganic phosphorus; (d)a second conduit intermediate the first solids separator and the firstinorganic phosphorus reactor for conducting the first liquid from thefirst solids separator to the first inorganic phosphorus reactor; (e) adigester for anaerobically treating the first mixture to provide asecond mixture; (f) a third conduit intermediate the first solidsseparator and the digester for conducting the first mixture from thefirst solids separator to the digester; (g) a second solids separatorfor separating the second mixture into a second liquid and biosolids;(h) a fourth conduit intermediate the digester and the second solidsseparator for conducting the second mixture from the digester to thesecond solids separator; (i) a second inorganic phosphorus reactor formaking inorganic phosphorus; (j) a fifth conduit intermediate the secondsolids separator and the first conduit for conducting a first portion ofthe second liquid from the second solids separator to the first conduitto combine the second liquid with the material; and (k) a sixth conduitintermediate the second solids separator and the second inorganicphosphorus reactor for conducting a second portion of the second liquidto the second inorganic phosphorus reactor.
 5. The system of claim 4,wherein the material is waste-activated sludge.
 6. The system of claim4, wherein the inorganic phosphorus is a magnesium ammonium phosphatehexahydrate.
 7. A system for producing inorganic phosphorus fromwastewater, comprising: (a) a first conduit for introducing a materialinto a first solids separator; (b) a first solids separator forseparating the material into a first liquid and a first mixture; (c) afirst inorganic phosphorus reactor for making inorganic phosphorus; (d)a second conduit intermediate the first solids separator and the firstinorganic phosphorus reactor for conducting the first liquid from thefirst solids separator to the first inorganic phosphorus reactor; (e) adigester for anaerobically treating the first mixture to provide asecond mixture; (f) a third conduit intermediate the first solidsseparator and the digester for conducting the first mixture from thefirst solids separator to the digester; (g) a fourth conduitintermediate the digester and the first conduit for conducting a firstportion of the second mixture from the digester to the first conduit tocombine the second mixture with the material; (h) a second solidsseparator for separating a second portion of the second mixture into asecond liquid and biosolids; (i) a fifth conduit intermediate thedigester and the second solids separator for conducting the secondportion of the second mixture from the digester to the second solidsseparator; (j) a second inorganic phosphorus reactor for makinginorganic phosphorus; and (k) a sixth conduit intermediate the secondsolids separator and the second inorganic phosphorus reactor forconducting the second liquid to the second inorganic reactor.
 8. Thesystem of claim 7, wherein the material is waste-activated sludge. 9.The system of claim 7, wherein the inorganic phosphorus is a magnesiumammonium phosphate hexahydrate.